Means for manufacturing pile fabrics



Jan. 6, 1970 l. L. THATCHER g i MEANS FOR MANUFACTURING FILE FABRICS Filed Jan. 5, 1966 3 Sheets-Sheet 1 Jan. 6, 170 1. 1... THATCHER 3A8$245 MEANS FOR MANUFACTURING FILE FABRICS Filed Jan. 5. 1966 3 Sheets-Sheet 2 I. L- THATCHER MEANS FOR MANUFACTURING FILE FABRICS Jan. 6, 1976 3 Sheets-Sheet :5

Filed Jan. 5, 1966 United States Patent 3,488,245 MEANS FOR MANUFACTURING PILE FABRICS Irvine L. Thatcher, Greenleaves, Marldon Road, Northowram, Halifax, England Filed Jan. 5, 1966, Ser. No. 518,912 Claims priority, application Great Britain, Jan. 8, 1965, 866/65; July 15, 1965, 29,992/65 Int. Cl. D04h 11/08 US. Cl. 156-435 6 Claims ABSTRACT OF THE DISCLOSURE Apparatus for manufacturing dyed pile fabrics comprising a rotating hollow drum having a surface. formed in a plurality of rows of cells, each cell being of predetermined size, depth and pitch, means to deliver a measured quantity of liquid dye to each cell and a notched yarn inserting means which pushes a loop of yarn into the liquid-filled cell to imbibe the liquid dye by capillary action, a roller adjacent the drum to feed a farbic backing coated with adhesive to the dyed loops, and heating means which sets the adhesive and dries the pile. A cutter may be used to cut the loops.

The invention pertains to pile fabrics such as carpets, rugs and similar floor coverings, upholstery materials and so forth.

The chief object of the invention is to obviate the need for conventional looms and all their necessary ancillary machinery and processes in the production of pile fabrics by providing a new or improved process and means or apparatus whereby pile fabrics can be simultaneously manufactured and dyed to any predetermined multicolour pattern or design of maximum clarity and delineation.

Another object of the invention is to render possible the production of simultaneously manufactured and dyed pile fabrics whose piles may be either looped or cut, as desired.

A still further object of the invention is to enable pile fabrics to be reinforced or strengthened during manufacture, if desired.

Other objects and features of the invention will be introduced into the sequel hereto where desirable or necessary.

Broadly, the apparatus or means for carrying the invention into effect includes a member, preferably comprising a rotary cylindrical or tubular drum, adapted to be intermittently rotated at predetermined speed through the medium of gear trains or other suitable means.

The outer face of the said member is covered with a multiplicity of cells or recesses of predetermined size, depth and pitch which cells are intended to serve a dual purpose, namely, to receive and contain dyestuif provided from a suitable source or sources of supply and to also co-act with means for insertion into the cells of ends of yarn from a suitable supply whereby the said yarn is simultaneously dyed and looped.

The looped yarn is thereafter passed into engagement with suitable pre-formed backing material suitably treated so that the outer ends of the loops become adhered or bonded to the said backing whereupon the now pile fabric is complete having a pile of uncut or looped nature. Alternatively, additional means may be associated with the apparatus for cutting the loops forming the pile to produce a cut pile fabric.

Also combined with apparatus or means according to the invention are suitable heaters for facilitating dyeing and for curing the bonding.

A clear concept and understanding of the invention in its broad aspect will best be gained with the aid of the accompanying drawings, in which:

FIGURES 1a, 1b and 1c are a schematic arrangement of apparatus (not to scale) illustrating the principle of the invention.

FIGURE 2 is a schematic front view of a fragmental part of the preferably rotary member or drum employed in the process and apparatus according to the invention.

FIGURE 3 is a side elevation of the rotary member or drum of the apparatus and other associated parts whose functions will be hereinafter described.

FIGURE 4 is an enlarged side view of a detail of the apparatus.

FIGURE 5 is an elevation diagrammatically illustrating the means for inserting dyestuff into cells of the apparatus.

FIGURE 6 is a diagrammatic view of netted reinforcement used as the backing for the dyed pile fabric made in the apparatus of FIGS. l-S.

FIGURE 7 is a diagrammatic view of the latch mechanism linked to the dye dispenser and of the solenoid which operates the mechanism electrically.

The drum 1 is of hollow or tubular cross-section of any desired length according to the intended maximum width of the fabric to be produced, the said drum being mounted on an axial shaft 2 supported in suitable bearings. Any suitable well known means such as gear trains and ratchet mechanism are related to the said drum and shaft assembly for intermittently rotating the drum for predetermined distances during operation, the gears being driven from any convenient or included power unit such as an electric motor.

As shown in FIGURE la, the outer face or periphery of the drum 1 is covered with a multiplicity of cells or recesses 3 predetermined size, depth and pitch so that the said cells form rows in aligned positions across the drum and around the same.

Located in proximity to the drum 1 is or are one or more rows of dye dispensers 4 corresponding in number and in pitch with the co-axial rows of cells in the drum. The outlet end or nozzle of each dispenser is of less diameter than the cells 3 in order that the said nozzle may register with and enter for a predetermined distance into its related cell, means being provided for intermittently advancing and withdrawing the several dispensers in correct timed sequence relatively to the rotary motion of the drum.

When the dispensers enter into the cells, measured quantities of dyestuff of desired colour are automatically dispensed into the cells, the said dispensers being connected by pipe circuitry or otherwise to a suitable source or sources of dyestutf supply (not shown) of predetermined colour.

Also arranged in proximity to the drum 1 is a yarn insertion unit or units comprising a row of plungers 6 corresponding in number and pitch to the co-axial or transverse ro-ws of cells in the drum. The plungers 6 are of slightly less diameter than the bores of the cells 3 and may have notched or otherwise suitably contoured extremities, the several plungers being arranged to intermittently engage and withdraw from the cells in correct timed relationship with respect to the intermittent rotary motion of the drum 1.

Arranged to co-act with the yarn insertion unit is a source of yarn supply of any suitable kind. For instance, the supply may comprise a roller or beam upon which are wound ends of yarn corresponding in number to the number of cells in each transverse row of the drum, or the ends of yarn may be carried upon bobbins or like packages mounted on a.creel or equivalent device.

Any suitable roller or other guide means 7 may be provided for controlling passage of the ends of yarn to the apparatus.

Also located in close proximity to the drum 1, at a convenient distance from the yarn insertion unit, are a number of rollers 8 between which latter and the periphery of the drum 1 a continuous length of backing material is intended to be passed from a suitable source such as a rotary beam. The backing material preferably consists of any suitable woven fabric but it must be understood that felt, knitted fabric, sheet plastics substance, rubber or any other suitable backing material could be employed. Secondary backing could be applied simultaneously or later, as preferred or if desired.

One surface of the backing material has a film or layer of suitable bonding agent applied thereto either prior to or during passage to the drum 1. The bonding agent may consist of any suitable well known type of rubber-based substance or a suitable synthetic resin.

Heater means 9 are included in the apparatus to preheat the backing 11 from the under side between the guide means 7 and the first roller of the plural roller means 8 and a further heater means 49 is mounted inside the drum, for expediting the dyeing and drying actions and other heater means 29 is provided above the backing and after the last of the rollers in roller means 8 in proximity to the bonding station of the apparatus for curing the bond. The heaters 49 and 29 serve to heat the bonding agent prior to contact with the yarn on the drum. In addition, means for cooling hot-melt bonding agents after application may be provided.

The foregoing description sets forth the pertinent features of the invention and the operation of the apparatus during manufacture of pile fabric is as follows.

When the apparatus or machine is started, the drum 1 is caused intermittently to rotate and sequentially advance the rows of cells 3 relatively to the dye dispensing and yarn insertion means 4 and 6. Then, as the rows of cells progressively pass the dye dispensers any or all of the cells in each row receives a charge of dyestuif 5 caused by the dispensers moving into engagement with the cells and automatically discharging measured quantities of dye. Preferably, this operation continues until the cells in a predetermined area of the drum are charged to produce a complete predetermined pattern.

As the drum continues intermittently to rotate ends of yarn are fed to the apparatus relatively to the yarn insertion means whose reciprocatory plungers 6 are timed and adapted to operate to press the corresponding ends of the yarn into the said rows of cells in the form of loops. The loops of yarns in the several cells almost instantaneously absorb the dyestulf in the cells and the said loops become dyed or coloured accordingly. Withdrawal of the plungers leaves the inserted and dyed loops of yarn in the cells (see FIGURE 1a).

During the yarn dyeing and inserting operation aforesaid other rows of cells in the drum are being automatically charged with dyestufi in desired manner; for instance, to repeat the pattern already completed on the drum.

As the dnum 1 moves further the outer ends of the loops of yarn 10 are brought into engagement with backing material 11 being fed from its source and the rollers 8 press the said backing onto the outer ends of the loops causing the latter to adhere or become bonded to the ap propriately treated surface of the backing 11. This is shown in FIGURES 1a and lb.

Because of the heater means 9 which preheats the backing and heater 49 in the drum which heats the dyed loops in the arrangement which is referred to above, the dyestuft' rapidly dries and the bonding action for the loops of yarn becomes complete.

Continuing movement of the drum and backing causes the loops of yarn to be automatically detached or withdrawn by the backing from the drum as diagrammatically shown at FIGURES 1c and lb and the completed dyed uncut 9r oop p e fabric can be rolled or f lded or otherwise dealt with by any suitable means for subsequent disposal of the fabric at a suitable station.

Should, however, it be required that some or all of the loops forming the pile be cut instead of remaining looped, suitable cutting means may be combined or associated with the aforesaid apparatus. These means could comprise a plurality of cutter blades 12 of tapered Or other suitable configuration arranged in a row relativel to the passing fabric with the number of blades corresponding to the number of cells in each row of the drum and as shown in FIGURE 1b. Hence, as the loops forming the pile of the fabric approach the blades the loops are engaged by the blades and continued movement of the fabric causes the loops to move further onto the blades until the loops are automatically cut thereby as shown at the right hand end of the fabric in FIGURE 1c.

Revolving brushes or vacuum operated means could be provided for removing any dust or fly resulting from pile cutting or other operations.

It will readily be understood that by immobilizing or discarding the dye dispensers and employing pre-dyed ends of yarn pile fabrics of merely one predetermined colour or consisting of variously coloured stripes could be produced according to the invention. Or natural undyed yarns could be employed.

A very effective manner for automatically dispensing dyestuff to the cells of the drum 1 as aforesaid is achieved by employing a row or rows of units, one of which units is illustrated in axial section in FIGURE 5 of the accompanying drawings.

It will be observed on referring to the said figure that a pipe or tube 15 is connected to a pipe 16 associated with a source of dyestuff supply. Housed in the bore of the tube 15 is a one-way valve in the form of a springloaded ball 17, suitably seated with respect to a seating in the pipe 16. I Slidably mounted on the external wall of the tube 15 1s a secondary pipe or tube 18 furnished with an outlet nozzle 19 housing a one-way valve also in the form of a spring loaded ball 20. The tube 18 is of greater length than that of the primary tube 15 to provide a chamber of predetermined volumetric capacity. When the secondary tube 18 is moved outwardly upon the relatively stationary tube 15 the valve 17 automatically opens and dyestuff from the supply pipe 16 flows into the aforesaid chamber. Immediately the direction of movement of the tube 18 is reversed the valve 17 automatically closes and the valve 20 automatically opens whereupon the predetermined charge of dyestutf contained in the chamber is expelled or discharged at the nozzle 19 into one of the cells of the drum 1 of the apparatus according to the invention.

The pipe 16 would carry a plurality of identical dispensing units corresponding in number and pitch or spaced relationship to the cells of the drum 1.

A useful possible addition to apparatus according to the invention are means for inserting reinforcement into the pile fabric being produced.

Such means could comprise a beam carrying any desired number of ends of strong yarn, string, wire or other suitable filaments adapted to be longitudinally introduced to the backing material immediately before the loops forming the pile are bonded to the backing.

Alternatively, a carrier or carriers could be mounted at either or both sides of the apparatus for inserting transverse reinforcing yarn, string, wire or other filaments into the pile fabric.

Or both longitudinal and transverse reinforcements may be employed.

A preferred kind of reinforcement, however, would be in reticulated or netted form as diagrammatically illustrated in FIGURE 6 where the reinforcement comprises strong yarn, string, wire or other suitable filaments 22 inserted by any suitable means so that the loops of the pile are enclosed by the reticulated arrangement of the said filaments.

A convenient manner of providing the aforesaid cells or recesses 3 in the rotary drum member 1 is illustrated in FIGURES 3 and 4 of the drawings Where the cells comprise identical tubular members ganged together in predetermined number and spaced relationship upon supporting devices 23 adapted to be secured to the periphery of the drum, the ends of the several devices being accurately located by providing lugs or keys 24 arranged to mate with recesses 25 formed in the drum.

In FIGURE 3 it will be observed that thirty rows of dye dispensers are associated with the drum the dispensers of each row being connected by a pipe such as 16 (FIG- URE 5) to a supply of dyestuff of desired colour. By arranging that certain of the dispensers in the first row operate to charge each advancing row of cells in the drum and that as each row of cells sequentially passes to the next row of dispensers where other predetermined cells also receive charges of dyestuif and so on throughout thirt rows of cells, any predetermined pattern of predetermined colour can be built up. The drum is continuing its intermittent rotary motion passes to the yarn inserting means and the predetermined pattern is dyed into the inserted loops, one row at a time.

Meantime, the uncharged cells of the drum sequentially pass to the dye dispensers and continue to function to repeat the pattern so that the production of dyed pile fabric is continuous and automatic.

The manner of advancing the dispensers towards the cells may be effected by electric solenoids, punched cards or any other suitable means.

To prevent commingling of the dyestuff by capillary action the outer looped ends of the yarn may be treated with any suitable substance prior to the aforesaid bonding action.

One system of controlling the dye dispensers 4 according to the invention can be understood by referring to FIGURE 5. One dispenser only is shown but any predetermined number are ganged together in a supporting head or unit located close to drum 1. The supporting head is adapted to be moved towards the drum 1, when necessary, by a driven cam or other suitable means whereby every nozzle of the Whole of the dispensers 4 enters into the corresponding cell 3 in the said drum. During this movement of the unit every dispenser receives a charge of dyestuif.

In FIGURE 7, there is shown the latch mechanism which is associated with the dye dispenser 4 and which is electrically actuated by a solenoid.

Associated with each dispenser 4, and as shown in FIG. 7, is a solenoid 30, a pivoted latch 31, a co-acting latch member 32 and a spring-loaded frame 33 linked to the dispenser.

When any or all of the solenoids 30 is or are energised in any desired manner the outer end of the latch member 31 pivots towards the solenoid and the corresponding frame or frames 33 and dispenser or dispensers 4 are automatically retracted by the spring 34, whereupon dyestutf in the retracted dispensers is ejected into the corresponding cells 3 as previously described.

What is claimed is:

1. Apparatus for manufacturing dyed pile fabrics comprising:

a hollow drum of tubular cross section mounted for rotation on a shaft;

a gear and ratchet mechanism operatively related to said drum and shaft assembly for intermittent rotation of said drum;

a multiplicity of cells formed in a plurality of rows in and extending transversely across the surface of said drum;

each of said cells having a predetermined size, depth and pitch for receiving a measured quantity of liquid dye of predetermined color prior to insertion of a yarn loop into said cell whereby the yarn loop imbibes said liquid dye by capillary action prior to assembling and bonding the dyed yarn to form the pile fabric;

dye dispensing means located adjacent said drum in alignment with a row of said cells, said dye dispensing means including a supply pipe containing dyestuif in liquid form, at least one row of dye dispensers each of which is fed by liquid dyestuff from said pipe and each of which is fitted with a nozzle capable of extending into said cell and with a spring-loaded valve for delivering a predetermined amount of liquid into the cell upon rotation of the drum to bring a row of cells into alignment with said row of dispenser nozzles; and

yarn inserting means located adjacent said drum and behind said dispensing means in relation to the direction of rotation of said drum, said yarn inserting means including a plurality of plungers arranged in a row for alignment with a row of said cells, notched means on said plungers adapted to engage a strand of yarn and, on reciprocation of said plunger, to bring said strand in loop form into a cell containing liquid dye dispensed from said dispensing means.

2. An apparatus for manufacturing dyed pile fabrics as claimed in claim 1, including roller feeding means adjacent said drum for feeding a backing fabric coated with adhesive to said dyed yarn loops and heating means for drying the dyed loops of fabric and drying and setting the adhesive coating on the backing fabric in forming the dyed looped pile fabric.

3. An apparatus as claimed in claim 2, including a plurality of cutter blades corresponding in number to the number of cells in each row of the drum, said blades cutting said loops after the backing is adhered and dried.

4. Apparatus as claimed in claim 3, wherein brush means and vacuum suction means are operatively associated with said cutting means to remove fragments of yarn after cutting.

5. Apparatus as claimed in claim 1, wherein said dye dispensers are reciprocated by cam means which are actuated upon rotation of said drum.

6. Apparatus as claimed in claim 5, wherein said dye dispensers are each fitted with a solenoid, latch means and a spring-loaded frame linked to the dispenser, said solenoid being energized by the movement of said drum and cam means to unlatch the latch means and retract the spring means to eject dyestulf from the dispenser.

References Cited UNITED STATES PATENTS 1,822,510 9/1931 Smith 156435 3,166,465 1/ 1965 Rahmes 15672 3,173,823 3/1965 Guinard 156435 3,235,438 2/1966 Wisotzky 161-62 HAROLD ANSHER, Primary Examiner M. F. MCCAMISH, Assistant Examiner U.S. Cl. X.R. 

